Exploiting the DNA of the Toyota Production System

Abstract

The recently published DNA coding for the Toyota Production System has been interpreted as a four-level prism model comprising vision, principles, toolbox, and learning organization. A series of material flow propositions relating to this model are advanced. This includes the smoothing of production, the strategic use of inventories, and the exploitation of industrial engineering techniques. These help explain and rationalize the apparent impact of ‘Japanization’ on a wide range of industries. A coherent picture thereby emerges from the available industrial evidence. This includes identification of a well-trodden improvement path from ‘traditional’ to ‘seamless’ operations based on uncertainty reduction leading to smooth material flow. Furthermore, TPS readily passes the predicated ‘transferability test’ between enterprises and between market sectors.